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The present study outlines the optimization of process parameters in the EDM of AA7178-10 wt.-% ZrB 2  composites. The composites were fabricated by using stir casting and the mechanical properties are evaluated. The mechanical properties of AA7075, AA7178 and AA7178-10 wt.-% ZrB 2  composites were reported. Scanning electron microscope (SEM) and energy dispersive spectrometry (EDS) analysis were used to characterize the composites. The fabricated composite material was machined using different process parameters based on Taguchi's L9 orthogonal array. Parameters such as current (I), pulse on time (PT-on) and pulse off time (PT-off) were varied. The response variables measured for the analysis are material removal rate (MRR) and surface roughness (SR). From the SN Ratio (SNR) analysis, it was observed that, current is the significant factor affecting both MRR and SR. ANOVA analysis was carried out to determine the percentage contribution of each factor to the responses. Further, a verification experiment was performed to confirm the performance of optimum parameters.

Synthesis, properties and EDM behavior of 10 wt.-% ZrB 2 reinforced AA7178 matrix composites